JPS6271628A - Manufacture of band-shaped form or form mat, which mainly consist of polymer material and can be laminated directly - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to directly laminable strip foams or foam mats consisting primarily of polymeric materials.

Conventional technology Strip foam or foam mat has its unique characteristics,
They are widely used, for example due to their low thermal conductivity, good sound absorption, good damping behavior and low apparent density.

Strip foams or foam mats are produced, for example, by continuous or discontinuous thermal foaming from so-called matrices, which are generally extruded, densified, containing all physically or chemically active blowing agents. Made of thermoplastic resin. This matrix is
It is heated, for example in a circulating oven, to a temperature that causes foaming of the matrix. Depending on the starting materials used, cell structures result, which may be closed or open-celled and may be crosslinked or non-crosslinked.

In order to improve the specific foam material properties, it is necessary to join strips or foam mats of different foams in a plane so as to obtain a foam bond. Furthermore, it is necessary to laminate the strip-shaped foam to the sheet or plate in a plane.

A reasonable cost and widespread method for joining various strip forms to each other or to sheets or plates is to briefly fuse the individual strips to a surface, for example using an open flame, and In the resulting viscous state, they are bonded to each other in a plane under the action of pressure, a so-called flame bonding. The prerequisite for this method is that the layers to be bonded consist of mutually compatible materials which adhere to the layers during surface heating and there permanently match with each other. Flame lamination, on the other hand, is impossible or difficult when bonding incompatible material combinations, such as polyethylene foam with PvC foam or sheets and foams of corresponding material combinations. be. Methods are already known for bonding such incompatible materials to each other.

For this purpose, for example, one of the two materials may be coated with an adhesive and subsequently bonded to the other material in the plane. Such adhesive bonding is, on the one hand, relatively expensive and, on the other hand, causes serious handling problems. It is also known to laminate the foams at their surfaces using hot-melt adhesive sheets in order to subsequently bond the thus pretreated foam strips with cover sheets or other foam strips by flame lamination. . This method is expensive since the production of melt-bonded sheets is expensive and therefore price-intensive.
Relatively expensive. The melt-bonded sheet (also known as a melt-bonded sheet) is also produced only in a certain minimum thickness, where this sheet may adversely influence the subsequent bonding, e.g. with regard to vapor diffusion behavior. requires extensive processing steps.

Problems that the Invention Aims to Solve An object of the present invention is to solve the problem of direct bonding with other strips or mats, in particular of materials not normally suitable for direct bonding with strip foams or foam mats. The purpose is to produce strip-like foams or foam mats by thermal foaming, which are also suitable for flame lamination. The method for producing such a strip foam or foam mat should also be easy and cost-effective, and in addition, handling of the strip foam or foam mat produced in this way should be problem-free.

Means for Solving the Problem This problem is solved according to the invention by combining a matrix consisting essentially of a polymeric material A with a suitable commercially available melt-adhesive sheet and at least one of its surfaces 5, i.e., in a planar manner. ,
This is then carried out by foaming (for example in a foaming oven using known methods). During this foaming process, the melt-bonded sheet is enlarged in a planar manner corresponding to the expanding matrix surface, without any other external influences, and its debris thickness is reduced correspondingly and uniformly. The strip foams or foam mats produced in this way are in this way very thin, yet very homogeneous hot-melt adhesive films that are eminently suitable for subsequent lamination with other strips. occurs.

The strip foams or foam mats produced by the method according to the invention which are mainly made of polymeric material A are in particular suitable for use with materials which are not normally suitable for direct bonding with strip foams or foam mats also made of material A. direct lamination with other strips or mats consisting of;
Particularly suitable for flame lamination.

By this invention! The lamination speed with the produced strip foams or foam mats is approximately 50 to 100 times faster than the lamination speed with the strip foams or foam mats produced according to the prior art by laminating hot-melt adhesive sheets.
5g is expensive.

The melt-adhesive sheet used for the inventive lamination of the foam matrix corresponds to the prior art,
The choice depends on the polymeric material A and the material B intended for subsequent coating. Generally, a sheet is selected consisting of a third material C which has good adhesion properties with Q on the one hand with material A and on the other hand with material B.

Significant advantages of the method according to the invention are that formma) IJ
For lamination with Lux, a hot melt adhesive, only the side of the hot melt adhesive, which corresponds to the side of the foam matrix, is needed.

On the other hand, when laminating a fully foamed strip foam with a hot-melt adhesive sheet, as is known from the prior art, the surface area of the hot-melt adhesive sheet is about 2.5 to 15 times larger. Needed. Depending on the foaming degree of the matrix, this results in a material saving of 60 to 93 inches for the hot-melt adhesive sheet-side compared to known lamination methods. Since in fact the hot melt adhesive sheet does not fall below a certain minimum thickness in the method according to the invention, material savings of up to 80% of hot melt adhesive sheet material are achieved.

A further advantage of the process according to the invention is that, by laminating the matrix with a hot-adhesive sheet, the matrix reduces the foam development foaming agent losses, so that the mass loss of the foaming agent is optionally reduced.

As a result, the method according to the invention makes it possible to achieve high bond strengths during subsequent flame lamination with other strips or mats, which far exceed that achieved with the prior art.

The melt-adhesive sheet can be laminated onto this during the manufacture of the foam matrix, for example by extrusion when smoothing the foam matrix, by laminating the melt-adhesive sheet onto the matrix using the residual heat of the matrix. 〇The bond between the foam matrix and the melt-adhesive sheet thus created is such that the adhesion of the melt-adhesive sheet on the matrix during subsequent foaming of the matrix is enlarged by the melt-adhesive sheet corresponding to the matrix surface. That is enough to ensure that. In the method according to the invention, no additional process steps are thereby necessary for laminating the hot-melt adhesive film.

Another advantageous embodiment of the invention provides that on one surface thereof the IJ Tsukusu material A has good adhesion properties and on the other surface it is prepared by the method according to the invention for subsequent lamination. A two-phase, commercially available melt-adhesive sheet is used which has particularly good adhesion properties to the polymeric material B, which has been previously provided on the coated strip foam. The use of two-phase adhesive sheets known per se is particularly advantageous, since in this case a particularly strong bond is created between the various strip foams or the strip foams formed according to the invention and the laminated sheets or plates. has been shown to be advantageous.

Another advantageous embodiment of the invention uses a melt-bonded sheet provided with slit-like recesses, which expand particularly uniformly with seven tricks during thermal foaming and prevent the formation of air bubbles between the foam and the melt-bonded sheet.

The present invention will be described in detail with reference to the following embodiments and drawings.

EXAMPLES Example 1 Polyethylene-striped foams are manufactured from closed-cell, cross-linked polyethylene having an apparent density of 30 kg/U3. Polyethylene strip foam is used for lamination.
vC - equipped with band-shaped foam or foam sheet. In the application described, the polyethylene strip produced according to the invention is used for the production of multilayer landing mats.

FIG. 1 illustrates that a wide slit die 1 is used to continuously extrude a polyethylene strip (matrix) 2 containing crosslinking and blowing agents. The thickness of the extruded strip is approximately 3 mm. Extrusion is carried out in accordance with conventional techniques at temperatures below the temperatures required for the crosslinking and foaming reactions. After extrusion, the strip matrix 2 is smoothed with a smoothing calender 3. During this smoothing process, two layers of melt-adhesive sheets 5 are applied to the matrix 2 via a feeding device 4.
applied on top. Due to the residual heat present in the matrix 2, the melt adhesive sheet 5 adheres to the matrix strip-shaped sheet 2. Xylo (X1ro) [used in the examples
The two-layer hot bonding sheet 5 of type V-193-1 from the company F] has a polyethylene side 6 and a quaternary olefin having a melting point of 90 DEG C. and a basis weight of about 489/rrL2.
The copolymer formulation and PvC-side 7 consist of a copolyester with a melting point of 126° C. and a base type 1 of 62/J/rlL”.

After the IJ Lux is smoothed, it is crosslinked and foamed in a continuous foaming furnace 8 together with the applied molten adhesive sheet 5. At this time, the surface of the polyethylene band is expanded, and thereby the surface of the applied melt-adhesive sheet is also expanded approximately 10 times. After passing through the foaming furnace, the apparent density of the polyethylene foam is about 30 kg/rIL3, the thickness of the strip-like foam is about 9 mm, and the basis weight of the melt-bonded sheet 50 evenly distributed on the surface of the polyethylene-strip foam 20 is about 11 mm.
．． ! 9/rrL2.

The cooled strip foam 20 is not viscous at its surface 500 and can be rolled up without special measures.

In a second process step, the strip foam 20 thus obtained, which consists essentially of polyethylene, is used for direct lamination with a PVC foam strip or foam sheet.

In the selected application, an open-cell PVC strip foam 9 with an apparent density of 90 kg/rrL3 and a thickness of 24 mm is laminated on both sides with a polyethylene strip foam 20 as envisaged according to the invention. is planned. Flame lamination of three strip-shaped foams - 41 then approx. 14 rn
/ min. The strength of the bond between the foam layers (
is then higher than the strength of the individual layers. The multilayer foam composites obtained from the composites by cutting are particularly suitable as sports and landing mats. FIG. 4 is a sectional view of such a sports mat.

Example 2 The polyethylene strip foam provided with the hot-melt adhesive sheet produced in the first example is bonded to a 0.4 mm thick ABS sheet by flame lamination.

The product thus obtained is further processed by deep drawing.

Example 3 A polyethylene matrix is laminated according to the invention with one layer of a melt-bonded sheet consisting of a quaternary olefin copolymer mixture (Fabrikat , followed by foaming in a foaming oven, where a polyethylene foam having an apparent density of 100 kg/m@3 is obtained. The polyethylene foam is laminated with a woven polyester knitted fabric on its surface provided with a melt adhesive sheet. The planar structure produced in this way is used as a jacket molding by deep drawing.

The method according to the invention can be applied, for example, to polyethylene-1pvc
-Applicable to almost all thermally foamed foams, such as polypropylene foams.

As well as the advantageous continuous method of implementation, it is also possible to laminate the foam matrix discontinuously with the melt-adhesive film and subsequently foam it.

[Brief explanation of drawings]

1 represents an apparatus for the production of strip-shaped foams according to the invention, FIG. 2 is a perspective view of a foam matrix with a melt-bonded sheet at point A--A according to FIG. 1, and FIG. FIG. 4 is a perspective view of the strip form at point B--B according to FIG. 1; FIG. 4 represents a multilayer landing mat;

Claims (1)

[Claims] 1. By thermal foaming from a so-called matrix consisting mainly of polymeric material A, usually a strip of foam consisting of material A or another consisting of material B which is not suitable for direct lamination with a foam mat. In a process for the preparation of foam strips or foam mats consisting mainly of polymeric material A, which are also suitable for direct lamination with the strip or mat,
The matrix, before thermal foaming, is laminated on at least one of its surfaces with a melt-adhesive sheet that corresponds to the surface and enlarges the matrix during foaming, whereupon the thus produced strip of foam or foam mat is made of material B. Process for the production of directly laminable foam strips or foam mats, consisting mainly of polymeric materials, characterized in that they are directly laminated with other strips or mats consisting of polymeric materials. 2. A method according to claim 1, wherein the hot melt adhesive sheet is laminated with the foam matrix during its manufacture using the heat present in the matrix. 3. The method according to claim 1 or 2, which uses a multilayer melt adhesive sheet. 4. Use a melt-adhesive sheet with a cutout part,
A method according to any one of claims 1 to 3.